In the motor manufacturing industry, single-point damage on enamelled wires has long been a hidden yet critical issue. These micro-defects are almost invisible to the naked eye, but even the smallest damage can reduce insulation performance and ultimately lead to motor failures.

Traditional saltwater testing methods are not only inefficient but also destructive — motors used for detection must be scrapped afterwards, resulting in significant production losses.

AIP’s pinhole insulation tester (AIP8935 Series) addresses this long-standing industry challenge. Using low-voltage, non-destructive testing technology, the system ensures highly accurate detection of enamel-wire damage without harming the motor itself.

Ⅰ.Industry Pain Points: Traditional Motor Testing Is Stuck

Detecting insulation damage on motor stator coils has always been one of the toughest challenges in the industry. Before the introduction of AIP’s innovative technology, the motor testing field mainly relied on two traditional methods:

• High-Voltage Method

Although suitable for mass production, this method is destructive and offers very low detection accuracy for single-point insulation damage.

• Saltwater Test

While more accurate in detecting defects, this method leads to the motor being scrapped after testing. It can only be used for sampling, not for batch production.

Both methods have significant limitations. Neither can achieve the combination of non-destructive, efficient, and high-accuracy testing, restricting overall quality control in motor manufacturing.

Ⅱ. Technological Breakthrough: A New Approach to Single-Point Damage Detection

After years of research, AIP achieved a major breakthrough in motor single-point damage detection technology in 2017.

The newly developed testing solution uses low-voltage, non-destructive detection to identify single or multiple damage points on enamelled wires without applying harmful high voltages or compromising insulation integrity.

Ⅲ.How the Technology Works

Under high vacuum conditions, a modulated voltage is applied between the motor windings and the housing, or between the coil and the silicon steel.

If a single-point insulation defect exists, a discharge phenomenon is triggered — allowing the system to accurately determine whether the stator is qualified.

This innovative method retains the strengths of traditional techniques while overcoming their weaknesses, achieving both high detection accuracy and complete non-destructive testing.

Ⅳ. Intelligent Applications: Comprehensive Testing for All Motor Scenarios

AIP designed three application modes tailored to different testing environments:

1. Mass Production Line Testing

· Single or dual workstation configurations available

· Supports both manual and automated testing

· Fast detection cycle: 6–10 seconds per unit

· Fully automated interface for seamless integration into production lines

2. Laboratory R&D Testing

· Advanced data analysis and statistical reports

· Ideal for sampling, product verification, and design optimization

3. Batch Repair & Maintenance

· Equipped with an observation window for spotting defects precisely

· Helps improve production processes, reduce costs, and enhance product quality

AIP specializes in global motor test solutions. With its cutting-edge low-voltage, non-destructive detection technology, the AIP pinhole insulation tester successfully overcomes the limitations of traditional testing methods.

It not only ensures precise detection of enamel-wire damage but also empowers manufacturers with intelligent tools and flexible configurations — delivering a complete, efficient, and reliable motor testing solution.

Looking to improve motor quality control, reduce scrap rates, and upgrade your testing capabilities?

Contact AIP today to get a customized motor test solution for your production needs!